Construction System Using Metal Stud Frame Element

ABSTRACT

A construction system includes a metallic stud definable in terms of an x, y, z coordinate system, in which the stud includes a z-axis elongate substantially rectangular integral web within a yz plane thereof; two xz plane surfaces, each projecting in a substantially x-axis direction, in which z-axis lines of dependence exist between a common web and said xz surface of the stud and of said first base in said yz plane of said web of the stud and tabs secured tabs integral with and elevated from at least one said xz plane surfaces. Further included is a concrete slab into which one set of the elevated tabs are wholly embedded prior to the hardening of the slab.

BACKGROUND OF THE INVENTION

The present invention relates to metallic stud frames of a type used in the formation of a frame of a residential, commercial or industrial structure, and is an improvement of the invention of my U.S. Pat. No. 6,988,347, entitled Metal Stud Frame Element.

Historically, frames of such structures were formed of either wood, steel or concrete. In the case of load bearing structures, it is common to use a steel bar, know as rebars within a poured concrete structure. The use of vertical light gauge steel studs, in lieu of wooden studs to accomplish internal framing within a wood frame structure, is also well known in the art. It is, however, not known to employ thin gauge vertical studs in combination with exterior wall concrete framing in which the vertical stud operates to define an offset the distance between an exterior poured concrete wall and an interior plasterboard wall which is secured to one surface of such a vertical steel stud.

A need for such a vertical steel stud frame element has arisen as a consequence of rapid on-site assembly high techniques employing thin external concrete walls which have developed in the construction arts. The present invention therefore relates to such vertical metallic stud in which one rectilinear surface thereof may be poured as a part of a process of casting of an exterior concrete wall, its base and/or load bearing resultant structure.

SUMMARY OF THE INVENTION

1. The inventive construction system comprises a metallic stud definable in terms of an x, y, z coordinate system, the system itself comprising: (i) a z-axis elongate substantially rectangular integral web within a yz plane thereof; (ii) two xz plane surfaces, each projecting within a substantially x-axis direction, in which xz-axis lines of dependence exists between a common web and in said xz surfaces of said web of said stud; and (iii) a plurality of tabs integral with and elevated from at least one said xz plane surfaces. Included is a concrete slab into which at least one set of substantially all of said elevated tabs of said plurality thereof are wholly embedded therein prior to the hardening of said slab.

It is an object of the invention to provide an improved element particular adapted for use with a concrete framing structure.

It is another object to provide a metallic stud of the above type which can function as an interior to exterior wall defining offset.

It is a further object of the invention to provide a vertical metallic stud capable of defining the shape and extent of vertical load bearing concrete columns within a poured concrete structure.

The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention and Claims appended herewith

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an inventive metallic stud in accordance with my invention and the X, Y, Z coordinate system associated therewith.

FIG. 2 is a transverse cross-sectional view taken through Line 2-2 of FIG. 1.

FIG. 2A is a transverse cross-sectional view taken through Line 2A-2A of FIG. 1.

FIG. 2AA shows a variation of the embodiment of FIG. 2A.

FIG. 2B is a transverse cross sectional view, similar to the view of FIG. 2A, however, showing a second embodiment of the inventive metallic stud.

FIG. 2C is a transverse cross-sectional view, similar to the view of FIG. 2A, however, showing a third embodiment of the metallic stud.

FIG. 2D a transverse cross-sectional view, similar to the view of FIG. 2A, however, showing a fourth embodiment of the invention.

FIG. 2E is an enlarged view of the tab of FIG. 2A.

FIG. 3 is an exploded view showing the stud frame of FIGS. 1 and 2A in combination with upper and lower system framing elements.

FIG. 4 is an assembly view of the exploded view of FIG. 3.

FIG. 5 is a view, further to the view of FIG. 4, in which a concrete base of a resultant structure has been formed.

FIG. 6 is a fragmentary bottom vertical sectional view of a resultant structure showing a yz plane tab of the inventive stud wall.

FIG. 7 is a xy sectional view of FIG. 6 showing the yz plane tab wholly embedded within a poured exterior wall.

FIG. 8 is a horizontal (yz) cross-sectional view of FIGS. 6 and 7.

FIG. 9 is an enlarged view of a tab of FIG. 2A embedded within the an exterior wall of FIG. 8.

FIG. 10 is a vertical view of a stud, similar to that of FIG. 1, but showing a different spacing between the tabs thereof.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the perspective view of FIG. 1, the present inventive metallic stud for use in the framing of construction systems may be defined by an x, y, z coordinate system which is also shown in FIG. 1. More particularly, an inventive stud 10 may be seen to include an integral web 12 having a z-axis elongate structure, which is substantially rectangular in cross-section from a first major base 18 and an opposing second major base 24, which bases are substantially parallel with each other, both of which depend from web 12 along z lines 14 and 16, in an xz plane. See FIG. 2. Further shown are tabs 19 which depend from first base 18 of stud 10, and which typically are punched therefrom with plane face or cross-section to produce a corrugated section.

Stud 10 is preferably formed of a light gauge steel in a range of 24 to 8 gauge. Certain surfaces of which may be corrugated.

The view of FIG. 2A is a cross-section taken along Line 2A-2A of FIG. 1.

More particularly, in FIG. 2A are shown said bases 18 and 14 from which sub-elements 26 and 26A respectively depend, and which are substantially parallel with web 12. A trapezoidal tab 19 depends from said stud base 18.

In the embodiment of FIG. 2AA of the sub-element 26A of FIG. 2A is eliminated from base of stud 110. FIG. 2A represents a preferred embodiment, as between the two, in which an x-axis dimension thereof increases as a function of y-axis directionality of the tab 19.

In FIG. 2B is shown a further embodiment of the invention which generally resembles that of the embodiment of FIG. 2A but in which an elevated tab 219 exhibits a generally polygonal shape. As such, in the embodiment of FIG. 2B, it is to be understood that an outermost end of tab 219 may define a square, hexogen, or any other polygon.

In FIG. 2C is shown a third embodiment of the invention in which tab 319 depending from base 318 defines a T-shape in the xy plane.

In FIG. 2D is shown a further embodiment in which tab 419, depending from base 418 of stud 410, defines a circular shape in the xy plane.

In all embodiments of FIGS. 2A to 2D, it is to be noted that the tabs need not be at right angles to the base 18 of the stud. Further, in one embodiment, the y-axis dimension of each of said tabs exhibits a ratio of about 1:1 to and axis, or width, dimension thereof. Further, an acceptable ratio of y to x axis dimension is in the range of 0.5 to 2.5.

Also, it is noted that any of said tabs may be corrugated, as indicated by the phantom lines of FIGS. 2A-2D.

The fashion of integration of frame stud 10 into a larger structure may be seen with reference to the exploded view of FIG. 3 in which three of the inventive metallic studs 10 are shown in vertical position relative to horizontal framing members 28 and 30. In FIG. 4, the elements of FIG. 3 are shown in assembly view.

In FIG. 5 the structure of FIG. 4 is shown, however, with the addition of a horizontal concrete footing 32.

The view of FIG. 7 is further to that of FIG. 5 in which a resultant structure, including a capstan 33, is shown which is cast over horizontal framing members 28 and 30. Further shown in FIG. 7 are rebars 35 within said capstan, and rebar 37 within footing 32. FIG. 9 is also a yz end plan view of FIG. 6, showing the vertical relationship between stud 10 and inner and outer walls of 34 and 36 respectively of a resultant framed structure. Shown within outer wall 34 is wire mesh 41.

In FIG. 8 is shown the manner in which tabs 19 of the metallic stud 10 are embedded within a thin concrete wall 34, which forms an exterior of a structure to be framed and as may be further seen in FIG. 9. Attachment of plaster boards 36 or the like to sub-elements 24 of the metallic stud 10 is also shown. Such attachment is typically effected through screw attachment, although other means of securement, i.e., glue or adhesion may be employed. As may be further noted in FIG. 8, studs 10 may be used to form vertical molds into which columns 38 and 40 may be poured to provide load bearing capability to the resultant structure.

The above described metal stud 10 constitutes a cost-effective means for rapid assembly of a large variety of structures which obviates entirely the need for wood, steel I-beams, or heavy steel rebars within concrete. Further, structures resultant from the use of stud 12 do not require large or massive quantities of concrete to produce a structure of suitable resistance to loads and stresses, both horizontally and vertically. In addition, because vertical concrete columns, such as columns 38 and 40, may be formed through the use of the inventive metallic stud, traditional truss structures may be placed thereupon where special purpose roofing designs are required.

While there has been shown and described the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that, within said embodiment, certain changes may be made in the form and arrangement of the parts without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith. 

1. (canceled)
 2. The system as recited in claim 13, in which said elevated tabs project in a substantially y-axis direction.
 3. The system as recited in claim 13, in which at least one of said xz plane surfaces comprises a longitudinal sub-element directed away from at least a portion of said web.
 4. The system as recited in claim 2, in which a relationship of a y-axis dimension of each elevated tab exhibits a ratio of 1:1 to an x-axis dimension of each said tab.
 5. The metallic stud as recited in claim 2, in which a relationship of a y-axis to x-axis dimensions of each elevated tab exhibits a range of ratios of 0.5 to 2.5:1 of each said tabs.
 6. The system as recited in claim 5, in which a z-axis spacing between said respective tabs on said xz planar surfaces comprises a range of 4 inches to 24 inches.
 7. The system as recited in claim 5, in which an xy plane geometry of each tab comprises substantially a T-shaped surface.
 8. The system as recited in claim 5, in which an xy plane geometry of each tab comprises a substantially circular surface.
 9. The system as recited in claim 5, in which an xy plane geometry of each tab comprises a substantially polygonal surface.
 10. The system as recited in claim 3, in which an xy plane geometry of each tab comprises substantially a wedge shaped surface, a major base thereof depending from an x-axis of each said sub-element.
 11. (canceled)
 12. The system as recited in claim 2, in which said tabs comprise corrugated surfaces.
 13. A construction system, comprising: (a) a metallic stud definable in terms of an x, y, z coordinate system, the stud comprising: (i) a z-axis elongate substantially rectangular integral web within a yz plane thereof; (ii) two xz planar surfaces, each projecting in a substantially x-axis direction, in which z-axis lines of dependence exists between a common web of said xz surfaces of said stud; and (iii) a plurality of tabs integral with and elevated from at least one said xz plane surfaces in which a dimension of an x-axis geometry of each tab increases as a function of an increase in the y-axis thereof; and (b) a concrete slab into which at least one set of substantially all of said elevated tabs of said plurality thereof are wholly embedded therein prior to the hardening of said slab. 